DE10205700A1 - Manufacture of composite molded product, involves coating dope cement on insert material surface and molding of resulting coated material - Google Patents

Abstract

The dope cement (4) is coated on a surface of an insert material (1). Subsequently, molding of the coated material is performed and a composite molded product (10) is obtained.

Description

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a manufacturing method for a Composite molded product to ensure the adhesion between a synthetic resin and a material used, such as metal, resin, inorganic To improve material or the like in injection molding.

Description of the prior art

Conventionally, composite products or composite cast products that each from (i) a smooth wooden panel with an upper layer of wood and (ii) egg nem synthetic resin core material, as materials for quality furniture or the interior used for luxury cars.

In addition, in areas such as soundproofing and soundproofing Materials, composite steel plates and various types of shielding materials, and especially in areas that have liability between steel plates and the adhesion and connection of a steel plate and a plastic materials include the use of plastic outer panels tested to the Improve weather resistance and reduce weight and costs adorn.

Typically, to obtain such composite molded products, one set or injection molding or injection molding performed, (i) an on Press material as an upper layer made of a metal, a syn prepared synthetic resin, an inorganic material or the like (ii) the back of the material used with a primer or Primer is coated, and (iii) the material used in a mold  is arranged for injection molding so as to inject synthetic resin and a synthetic resin base on the back of the material used to form.

However, in this method the time during which the primer or Primer is kept active, short. Accordingly, injection molding should in a very short time after coating using the Pri be carried out. In addition, such coating under Use of a primer or primer immediately before the injection pour. Accordingly, it is difficult to use one Coat material evenly with the primer if the shape of the forth product to be delivered is complicated. Liability between the used material and the base resin inferior in this process; As a result, molded or cast products can have parts that stick out or break away.

SUMMARY OF THE INVENTION

In view of the above circumstances, it is an objective of the present Invention, a manufacturing process for a composite molded product watch to the liability between the used or material and the Improve base resin.

Therefore, the present invention provides a manufacturing method for a composite molded product, which comprises the following steps:
Coating an inserted material with coating cement; and
Subjecting the material used, which is coated with coating cement, to injection molding.

The present invention also provides a manufacturing method for a composite molded product, comprising the following steps:
Coating a material used with a primer or a primer;
Coating the surface of the primer with coating cement; and
Subjecting the material used, which is coated with the coating cement, to an injection molding.

In the aforementioned methods, the top cement is typically used obtained by dissolving a synthetic resin in a solvent, wherein the synthetic resin is injected with the synthetic resin upon injection is press molding or synthetic resin, which with the injected syn thetic resin is compatible.

According to the present invention, liability is between the used th material and the base resin excellent; accordingly is the generation of inferior products with parts that break away or protrude, unlikely. In addition, a surface material in which the used material is coated with the coating cement, a low Degree of exaggeration on; Accordingly, stamping or the like for the Forming of the surface material easily carried out after coating become.

Furthermore, sufficient time can be saved according to the coating cement for starting injection molding. Therefore, even if the shape of a product to be manufactured is complicated before the plate is formed the shape evenly coated with the coating or doping cement the. In addition, the plate has a very low after coating Degree of exaggeration; Therefore, stamping or the like can be used for the mold the plate can be easily carried out.

The present invention also provides a method of manufacturing a composite product comprising the following steps:
Applying a solution comprising a first synthetic resin and a solvent over a substrate to form a first layer comprising the first synthetic resin; and
Forming a second layer having a second synthetic resin compatible with the first synthetic resin of the first layer.

This method can further include the step of removing the solvent to form the first layer over the substrate, or the step coating the surface of the substrate with a primer or Primer. In the aforementioned method, the second layer can be on the first layer can be formed by injection molding. Typischerwei The substrate is at least one of the following materials represents: metal, resin and inorganic material.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a general and schematic cross-sectional view showing the structure of an example of the composite molded product, which is made using the manufacturing method according to the present invention forth.

Fig. 2 is a general or schematic cross-sectional view showing an example of the arrangement in which the surface material is placed in the cavity of a mold used for injection molding, according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following are exemplary embodiments according to the present invention described in detail.

Fig. 1 is a general cross-sectional view showing the structure of an example of the composite molded product of the present invention was prepared by use of the manufacturing method according to.

In the figure, reference numeral 1 indicates a material used. This material used is previously formed to have the shape that corresponds to the shape used in insert molding, that is, a shape that roughly corresponds to a final composite product. One of the surfaces of the inserted material 1 is treated to form a surface-treated layer 2 . This surface-treated layer 2 is coated with a primer or a primer in order to have a primer film 3 . The primer film 3 is then coated with a coating cement or a doping element, so that a coating cement film 4 is provided so that a surface material 5 is obtained.

In the present invention, the surface-treated layer 2 and the primer film 3 can be omitted.

As shown in Fig. 2, the surface material 5 is placed in the cavity of a mold 7 used in injection molding in such a manner that the coating cement film 4 faces the cavity (ie, the material 1 used ) towards the wall of Form 7 ). The shape of the cavity in the shape 7 corresponds to the shape of the ultimately molded or cast product. Then, the injection molding is carried out in such a manner that synthetic resin is injected toward the overlay cement film 4 of the surface material 5 , whereby the synthetic resin and the surface material 5 are combined. This composite is then removed from the molds 7 and 8 of the injection molding, so that the composite molded product 10 consisting of the surface material 5 and a base resin layer 6 is obtained.

The material 1 used in the present exemplary embodiment is metal, resin, inorganic material or the like.

Typically aluminum, an aluminum alloy, stainless steel, Koh lenstoffstahl or copper can be used as metal.  

Polycarbonate, polyester / polycarbonate, polyethylene, polypro pylene, polyethylene terephthalate, poly (methyl methacrylate) or the like be used.

Aluminum oxide, glass, ceramics, concrete, natural stone or the like can be used.

At least one of the surfaces of the material used is treated to improve the adhesion, as a result of which the surface-treating layer 2 is formed.

If the material used is metal, a surface treatment (method) called Alumite, Alodine (Alocrom), or etching or the like can be applied. If the material used is 1 resin or an inorganic material, then grinding, blasting with steel sand or blasting or the like can be used as a surface treatment.

Here, even if the surface treatment is omitted in the present invention, the coating cement film 4 provides sufficient adhesive strength between the material 1 used and the resin base layer 6 .

The primer or the primer in the present exemplary embodiment can be epoxy, urethane, rubber, acrylic, polypropylene or a vinyl paint (or Coating). Such a paint is generally used for liability, Painting, coating, laminating or bonding applied to Alumi nium, aluminum alloys, stainless steel, carbon steel, copper, polycarbo nat, polyester / polycarbonate, polyethylene, polypropylene, polyethylene Terephthalate, poly (methyl mathacrylate), aluminum oxide, glass, ceramics, Concrete or the like.  

A concrete example of the epoxy primer is a two-liquid epoxy Primer with main components made of (i) multifunctional epoxy resin, as in for example, cyclic fatty acid epoxy resin of the glycerin type, epoxy resin with Modified dimer acid, or a reaction product between bisphenol A and Epichlorohydrin, and (ii) polyamine, such as a polyamino amide Compound, an aliphatic polyamine, a cyclic aliphatic polyamine or an aromatic polyamine.

The following are concrete examples of the urethane primer: Liquid urethane primer with main components from (i) multifunctional Polyisocyanate, which is a multifunctional polyisocyanate compound an isocyanate group at the end, and (ii) polyol such as polye ther polyol or polycarbonate polyol, and a one-liquid urethane primer with a main component made of multifunctional polyisocyanate.

The following are concrete examples of the rubber primer: more natural Rubber, styrene-butadiene rubber, polybutadiene rubber, polyisobutylene, Polychloroprene, polyacrylate rubber and polyvinyl ether rubber.

The following are concrete examples of the acrylic primer or acrylic Primer: multifunctional methacrylic acid ester and multifunctional acrylic acid re-esters.

The following are concrete examples of the polypropylene primer: Polypro pylene and chlorinated polypropylene.

The following are concrete examples of the vinyl primer: polyvinyl butyral, Polyvinyl formal, polyvinyl acetacetal, and vinyl ethers such as Di vinyl ether or dibutyl vinyl ether.

The material 1 used or the surface-treated layer 2 is coated with one or more layers of the primer. A method such as printing, spraying, rolling, or flow coating can be used for primer coating.

The surface that is coated with the primer is dried at a temperature from room temperature to 50 ° C., whereby the primer film 3 is formed. The thickness of the primer film 3 is 1 to 100 μm, preferably 5 to 20 μm.

The dopant cement used in the present embodiment is a solution obtained by dissolving a synthetic resin in a solvent, which synthetic resin is used for the base resin layer 6 or has compatibility with the base resin layer 6 . Such a coating cement has an excellent adhesion to the material 1 used as an adhesive.

The following are concrete examples of the aforementioned synthetic Resin: (i) styrene resin such as acrylonitrile-butadiene-styrene Copolymer (hereinafter abbreviated as "ABS"), acrylonitrile-styrene copolymer (hereinafter abbreviated as "AS"), or polystyrene, (ii) vinyl polymer resin, such as for example polyvinyl chloride or polyvinylidene chloride, (iii) acrylic resin, such as for example polymethyl methacrylate, (iv) polycarbonate resin, (v) polyamide resin, (vi) polyolefin resin, such as polyethylene or polypropylene, and (vii) polyester resin such as polyethylene terephthalate or Po lybutylen terephthalate. These types of resin are used alone or as a mixture of two or more types of resin to be mixed are used. If a difficult one synthetic resin to be dissolved, such as polyethylene, is used is a powder of this synthetic resin with easy to dissolve synthetic resin, such as or mixed in ABS resin suspergiert.

The solvent can be acetone, methanol, isopropanol, toluene, xylene, Me thyl acetate, isobutyl acetate, butyl acetate, methyl ethyl ketone or with methyl Be isobutyl ketone. These types of solvents are used individually or in  Mixture used, according to the type of synthetic resin that is dissolved in the solvent.

The material 1 used can be coated directly with such a coating cement, or the surface-treated layer 2 can be coated with the coating cement, or the primer film 3 can be coated with the coating cement. The coated part is then dried in an atmosphere at a temperature of from room temperature to 50 ° C, whereby the sealing cement film 4 is formed. Similar to the primer, a method such as printing, spraying, rolling or flow coating can be used for coating with the top cement.

The thickness of the coating cement film 4 is 5 µm or more, preferably 25 to 70 µm.

The following are concrete examples of the synthetic resin from which the base resin layer 6 is made: (i) styrene resin such as acrylonitrile-butadiene-styrene copolymer (hereinafter abbreviated as "ABS"), acrylonitrile-styrene copolymer (in abbreviated as "AS"), or polystyrene, (ii) vinyl polymer resin, such as polyvinyl chloride or polyvinylidene chloride, (iii) acrylic resin, such as polymethyl methacrylate, (iv) polycarbonate resin, (v) polyamide resin , (vi) polyolefin resin such as polyethylene or polypropylene, and (vii) polyester resin such as polyethylene terephthalate or polybutylene terephthalate. These types of resin are used alone or as a mixture of two or more types of resin that are mixed.

Since the coating cement film 4 is compatible with the base resin layer 6 , the degree of adhesion between the coating cement and the base resin is excellent regardless of the elapsed time, that is, even after a few hours or days have passed. In addition, after the inserted material 1 is coated with a coating on a plate shape with the coating and then dried, the plate may be subjected to cutting work or press working so that a desired shape is formed. Accordingly, even if the shape of the surface material 5 is complicated, the plate can be coated with the coating cement uniformly before the shape is formed.

The different combinations between the material used, the Surface treatment, the primer, the coating cement, the solution medium and base resin that are possible are shown in Table 1.

Table 1

The composite molded product 10 , which is formed by the previously explained process, has sufficient adhesion between the material 1 used and the base resin layer 6 ; thus, low-quality products are unlikely to be created with a part that breaks away or protrudes. In addition, the surface material 5 , in which the material 1 used is coated with the coating cement 4 , has a very low degree of elevation; thus stamping or the like for the shaping of the surface material 5 can easily be performed after coating.

Practical examples are explained below.

First, the coating cement was made under the following conditions provided: 40 g ABS resin (product name: Stylac-ABS, manufactured by Asahi Ka sei Corporation) tablets were dissolved in 100 g acetone. This solution was diluted with the same amount of toluene, making the coating ment was manufactured.

In the next step, after a surface-treated side egg thin aluminum plate with a thickness of 0.5 mm with a primer was coated, the coated side continues with the previously mentioned over traction cement coated. The coated side was then dried that a coating cement film was formed.

Similar processes were used for different types of primers and for under different thicknesses (µm) of the coating cement repeated. After loading layers with the covering cement became any thin aluminum plate for egg Let stand at normal temperature for several days or months sen. The thin aluminum plate was then placed in the cavity of a mold grades used for injection molding and ABS resin (Pro Product name: Stylac-ABS, manufactured by Asahi Kasei Corporation) for training that of the base resin layer was injected into the mold, so that a ver cast product was obtained.  

The strength of the adhesion between the thin aluminum plate and the base Resin layer for each composite cast product was measured. The Messgeb nisse are shown in Table 2.

Table 2

Referring to Table 2, each composite cast product that uses the primer and the coating cement, in which the thickness of the coating tensile cement is 25 to 70 microns, sufficient adhesion, even if one or more days or months after coating with the over traction cement has passed.

The material 1 used can be wood, in which case (i) the surface treatment referred to as abrasion can be used or no surface treatment can be carried out, (ii) the primer is not always necessary (ie can be used), (iii) the above-mentioned coating cement can be used, and (iv) synthetic resin as explained above can be used as the base resin layer.

Although the invention is detailed with reference to its preferred Exemplary embodiments and certain described alternatives are described it should be clear that this description is only exemplary and not in one restrictive sense should be interpreted. It is also clear that numerous Changes in the details of the embodiments of the invention and Additional embodiments of the invention are clear and carried out who that can be done by people with average expertise under Be access to this description. Such changes are intended and additional embodiments through the mind and true order catch the invention as claimed.

Claims (9)

1. A process for producing a composite cast product which has the following steps:
Coating a material used with a coating or doping element; and
Subjecting the material used, which is coated with the coating cement, to an injection or injection molding process. 2. A method of making a composite molded product comprising the following steps:
Coating a material used with a primer or primer;
Coating the surface of the primer with a doping or overlay cement; and
Subjecting the material used, which is coated with the coating cement, to an injection or injection molding process. 3. Method of making a composite molded product, according to Claim 1, wherein the coating cement is obtained by dissolving egg nes synthetic resin in a solvent, the synthetic resin is an injected synthetic resin during injection or on is injection molding or synthetic resin that is injected with the synthetic resin is compatible. 4. Process for making a composite cast product Claim 2, wherein the coating cement is obtained by dissolving egg nes synthetic resin in a solvent, the synthetic resin is an injected synthetic resin during injection or on is injection molding or synthetic resin that is injected with the synthetic resin is compatible.   5. A method of manufacturing a composite product comprising the following steps:
Applying a solution comprising a first synthetic resin and a solvent over a substrate to form a first layer comprising the first synthetic resin; and
Forming a second layer comprising a second synthetic resin compatible with the first synthetic resin on the first layer. 6. A method of manufacturing a composite product according to claim 5, further comprising the step of:
Removing the solvent to form the first layer over the substrate. 7. A method of manufacturing a composite product according to claim 5, further comprising the step of:
Coating the surface of the substrate with a primer or a primer. 8. A method for producing a composite product according to claim 5, wherein the second layer on the first layer by injection molding is formed. 9. A method for producing a composite product according to claim 5, wherein the substrate is at least one of the following materials: Me tall, resin and inorganic material.